Recently, AIR ENERGY examined the role of Receivers in the Compressed air system; this time, we’d like to examine condensation drainage. Some Auto Drains cost money, and some save money.
Condensate is an unavoidable by-product of producing compressed air. For example, a 30 kW compressor with a free air delivery of 5 m³/min would generate approximately 20 litres of condensate per shift! Hot air from the compressor is saturated with water vapour, but as it cools, more and more is precipitated as condensate. It is crucial to remove this liquid from the air system using reliable condensate drainage. This prevents system failures, costly production downtime, and corrosion. Condensate collects at several points within every compressed air system.
1. Centrifugal Separator: This mechanical separator separates the condensate from the air by means of centrifugal force. For optimum performance, each compressor should be equipped with its own separator. Some brands of compressors include this internally.
2. Air Receivers: They have a number of functions, including the storing of compressed air, and aiding the process of separating condensate from the air via gravity. The large surface area of the air receiver allows the dissipation of heat and consequently cools the air further and enhances the separation of condensate.
3. Autodrains on Filters: These are mostly internal float operated but can be external – allow condensate separated by the filter element to be removed from the airstream.
4. Autodrain on the Receiver: The largest volume of condensate is often precipitated here. This can be released by a manual valve, but many Service Technicians can tell of experiences where this gets neglected, and the receivers fill up with dirty condensate.
5. Autodrain on Dryer: These are generally integral to the dryer, but we recommend always selecting a model with electronic sensing, not a timed solenoid.
There are three types of Autodrains which are mainly used:
A. Float Drains: Float drains traditionally replaced manual drainage, which relied on staff remembering to open drain valves manually. It was inefficient and highly unreliable. However, even using float drains can still malfunction due to dirt and contaminants in compressed air.
B. Solenoid Valves: time-controlled solenoid valves are more reliable than float drains but must be checked regularly for clogging and contamination. Climatic variations in the daily humidity determine the volume of condensate. A timed solenoid can be set with insufficient cycles, creating a build-up of condensate or opening too often, discharging and wasting compressed air and the dollars spent compressing that air. Incorrectly adjusted valve opening period and duration can cause air losses and increased energy consumption.
C. Condensate drains: It is equipped with level-sensing control are widely used today. These drains utilize electronic sensors instead of traditional floats, which are prone to faults. This innovation reduces issues caused by dirt or mechanical wear that can affect float-operated drains, resulting in more reliable operation.
Furthermore, the automatically controlled valve opening periods prevent air losses (which also occur with timed solenoid valves). Additional advantages include automatic self-monitoring and the capability to transmit signals to a central control system.
To allow for proper installation, a shutoff valve should be fitted between the equipment and the condensate drain so that it is kept on during maintenance to ensure the compressed air system remain online. Air Energy is experienced in all aspects of pipework and compressor design and selection. Modern pipe systems like Europress, Unipipe, or Maxair make installation much faster and superior.
The key to extraordinary performance lies in the extra quality and service you receive from AIR ENERGY. Call us now at 1300 139 559!